Process for the manufacture of molded sugar items



Jan. 28, 1969 R. D. JOFFE ETAL PROCESS FOR THE MANUFACTURE OF MOLDED SUGAR ITEMS Filed Jan. 20, 1967 n mg; m w w 4.7 r m i L4 7 V Z a a 3% United States Patent 9 Claims ABSTRACT OF THE DISCLOSURE A process for manufacturing molded sugar articles wherein granulated sugar is moistened with a wetting agent and then placed in a mold which is vibrating to compact the moistened sugar after which the molded sugar is exposed to heat and cooling and further vibration to free the completed molded article from the mold.

This invention relates generally to the confectionary industry and more particularly to a process for the manufacture of molded sugar articles, particularly those such as molded, hollow sugar novelties such as panorama Easter eggs and other novelty items.

In the past decorative articles of manufacture such as Easter eggs have been manufactured by several different methods, each of which is time consuming, expensive and fails to produce a uniform product.

One of the prior methods was a crystallization process wherein sugar and water is brought to a boil forming super-saturated syrup. The syrup is then poured into a female mold and let stand for a given length of time during which sugar crystals form along the walls of the mold into which the syrup has been poured. The size of the crystals and the speed of precipitation are determined, among others, by temperature, humidity, pressure, degree of saturation of the solution, agitation, etc. Rapid crystallization, however, results in a weaker shell.

After the specified crystallization has taken place along the walls of the mold, the excess syrup is poured from the mold. The remaining sugar crystal shell is allowed to dry within the mold, after which the shell is removed from the mold. The shells produced by this method are fragile, and

' to make them strong would be economically unjustifiable.

Because of the inherent property of sugar crystallization the shells must remain white in color unless an additional and costly step for coloring the shells is introduced to the manufacturing process. This entire proce s is slow, tedious and expensive in relation to the number of shells produced.

A second method which has been employed to manufacture hollow molded sugar items is that of placing properly moistened granulated sugar directly into the female section of the mold after which the sugar is compressed. This entirely filled female mold is inverted and the moistened sugar within is deposited from the mold onto a surface to dry. After a length of time depending on temperature, humidity, pressure and desired wall thickness, the remaining moistened sugar is scooped from within the now dry outer surface thus leaving a shell of sugar which must further dry before additional processing.

There is no uniformity to the molded shells in this method due to the fact that the scraping out of the interiors is a manual operation. Another disadvantage inherent to this method is that the thickness of the shell is necessarily of greater dimension to avoid weakened walls due to the lack of uniformity. This method results in a great deal of waste in the scraping of the sugar, is very time consuming, and cannot be easily employed in a production line basis due to the costs and time involved.

It is an object of this invention to provide a process whereby molded sugar articles can be manufactured using high speed production techniques which the time necessary for the manufacture of the molded article will be greatly reduced thereby substantially reducing the cost of production.

Another object of the invention is to provide a process for manufacturing molded sugar articles whereby the drying and hardening time of the molded sugar article is speeded up.

A further object of the invention is to provide a process for manufacturing molded sugar articles wherein molded sugar articles can be made in a uniform thickness and size, employing vibrating pressure to form the molded article.

It is a further object of the invention to provide a method for manufacturing molded sugar articles employing vibration and pressure and both heating and cooling in the manufacturing steps to form molded articles of uniform size and shape and to speed up the manufacture of the molded article.

Further it is an object of the invention to provide a process for the manufacture of molded sugar articles whereby numerous articles can be molded at the same time in accordance with the technique to be set forth further herein.

A further object of the invention is to provide an inexpensive method by which articles can be molded at great speed, and reduced cost, employing both heating and cooling of the molded sugar articles of uniform size, thickness and shape.

These, together with the various ancillary objects and features of the invention, will become apparent as the following description proceeds are attained by this process of manufacturing of molded sugar articles. The steps employed in the process are illustrated in the accompanying drawing by way of example only wherein:

FIG. 1 is a schematic perspective view depicting the various parts of the mechanism employed to manufacture molded sugar articles in accordance with the process of the invention;

FIG. 2 is a sectional view taken along the line of 2-2 of FIG. 1 showing the method of mounting of the male mold section on the vibrating table, the female mold section and sugar being molded therebetween;

FIG. 3 is an exploded vertical sectional view of the male and female mold with the molded sugar article shown in the female mold;

FIG. 4 is a top plan view of a plurality of male mold sections mounted on a support;

FIG. 5 is a vertical sectional view taken along the plane of line 4-4 of FIG. 4;

FIG. 6 is a top plan view of a plurality of female molds which are interconnected to register with the male molds; and

FIG. 7 is a side elevational view of the molded sugar article partially in section showing the molded sugar article which has been manufactured in accordance with the process of the present invention.

With continuing reference to the accompanying drawings wherein like reference numerals designate similar parts throughout the various views, the process of the present invention is practiced as follows.

Granulated sugar of various sizes as desired is thoroughly mixed with natural gum, starch compounds and water which forms a binding solution. During the mixing process for the granulated sugar with the binding solutions, certain U.S.P. coloring material may be added in order to give the moistened granulated sugar desired color.

Further during the mixing process fiavorings may be added as desired so as to impart to the sugar a particular taste such as pepermint, raspberry, cherry or the like.

After the granulated sugar has been thoroughly mixed with the binding solution and the color and flavorings added, the mixed moistened sugar is then placed into a tray generally designated as 14 which tray rests upon a high speed vibrating bed 16. Female mold sections 30 are filled with the moistened sugar from the tray 14 after which the female mold 30 is fitted to the male mold 22 to compress the moistened sugar utilizing manual, mechanical or hydraulic pressure. Extending upwardly from the vibrating bed 16 are a plurality of male mold holding support members 18 to which cross members 20 are removably secured. The cross members 20 have afiixed thereto a plurality of male mold sections 22. It is to be understood that the molds illustrated herein are purely for purposes of illustration and there is no limitation whatsoever as to design, configuration, or the number of mold sections that may be employed simultaneously.

Female mold sections are generally designated as 26 comprising a plurality of female molds 28 which are of corresponding size to the male molds 22. The female molds 28 are mounted to cross brace means 30 by Welding or the like so as to maintain the female molds in exact relationship to each other so as to correspond and register with the male molds 22.

The female mold section 26 is then placed in position to receive the moistened granulated sugar with the coloring and flavoring already added thereto, by either of two methods. In the first method the sugar medium is scooped up thereby filling each of the female molds 28. In the second method the sugar medium is deposited into the female molds 28 filling them exactly with a premeasured amount from an overhead hopper.

Due to the fact that the male mold sections 22 are supported by supporting bars 18 on the vibrating bed, a high speed vibration is imparted to the male molds which causes the moistened granulated sugar which has been picked up in the female molds 28 to be compacted and spread evenly within the mold cavity. After the necessary compacting and distribution of the moistened granulated sugar has taken place within the mold the female mold section 26 with the compacted moistened granulated sugar therein is removed from the male molds 22 and then placed upon a conveyor belt 36 which conveyor belt is travelling at a speed which is variable depending upon the length of time needed to harden the sugar in the mold. The conveyor belt causes the compacted granulated sugar in the female mold section to enter into a high temperature or infra-red heating oven 38. It is to be noted that the infra-red variable heat oven produces hot dehumidified air which causes the sugar in the female mold section to cure by hardening in a predetermined shape in a short time, from two to six minutes. The heating oven is of such design as produces intense heat in a restricted area thereby evaporating any moisture which may be in the atmosphere in the oven. The heating oven 38 is maintained at such temperature which will cause evaporation of the binding solution and further solidification depending upon the thickness of the sugar shell, the size and shape of the item, the amount of sugar in the mold section, as well as any other factors which might affect the drying cycle. The temperature is maintained between 200 and 2400 degrees Fahrenheit depending upon the thickness of the sugar to be molded, and upon the amount of moisture and binding solution which has been added to the sugar. As the conveyor belt passes through the oven 38 the moistened sugar contained within the female mold 28 is dried forming a relatively hard, uniform thickness, molded article.

After the hardening of the granulated sugar has been completed the molded sugar in the mold 26 is then passed on the conveyor belt 36 into a cooling chamber 40. The cooling chamber 40 is an air cooled dehumidified area wherein the temperature is maintained between 35 and 75 degrees Fahrenheit. Once within the cooling chamber the molded sugar article within the molds 28 is rapidly cooled. The conveyor belt 36 then transports the female molds 22 with the cooled molded sugar articles onto a second vibrating tray 42 which loosens the molded article from the female mold so it is ready for further processing. The vibration imparted to the second tray 42 is separate and distinct from that provided to the tray 16 and generally will be of a higher frequency than that imparted to tray 16.

It is to be understood that either or both the male mold 22 and the female molds 28 may be coated with a. nonstick coating such as a vegetable oil, mineral oil, FDA. approved silicone resin coating or some other coating such as Teflon coating which will aid in and facilitate the removal of the granulated moistened sugar from the male molds 22 and the molded sugar article from the female molds 28.

A latitude of substitution, change and modification is intended in the foregoing disclosure and in some instances certain features-of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a maner consistent with the spirit and scope of the invention herein.

What we claim is:

1. A process for manufacturing molded sugar articles comprising the steps of moistenin-g granulated sugar with a wetting agent, placing said moistened sugar within a female mold section, bringing said female mold section against a vibrating male mold section compacting the sugar, applying pressure to said female mold section further compacting the sugar, removing said female mold section from said male mold section, then passing said female mold section with said molded and compacted sugar into a zone of heat to partially finish a molded article, thereafter cooling said female mold and said molded article, and then vibrating said female mold and said molded article to free said molded article from said female mold to facilitate removal of said molded article from said female mold.

' 2. A process of forming molded sugar articles as set forth in claim '1, wherein each of said mold sections are coated with non-stick food coating selected from the group comprising oil, silicone resin, and polytetrafiuoroethylene.

3. A process of forming molded sugar articles as set forth in claim 1, wherein said zone of heat comprises an infrared, de-humidifying oven maintained at a temperature ranging from 200 F. to 2400 F. for a period of time ranging from two to fifteen minutes.

4. A process of forming molded sugar articles as set forth in claim 1, wherein said zone of heat is provided by a high intensity oven maintained at a temperature ranging from 200 F. to 2400 F. and said molded sugar article is passed through a dehumidifying cooling chamber maintained at a temperature ranging from 35 F. to 75 F. for a period of time until said molded sugar article is cooled.

5. A process of forming a molded sugar article as set forth in claim 1, wherein said female molds containing said compacted moistened granulated sugar are placed on a variable speed mechanical conveyor for transporting female molds first into said zone of heat, then into a dehumidifying cooling booth, and then depositing said female molds on a second vibrating surface to free said molded sugar article from said female molds.

6. A process for forming molded sugar articles as set forth in claim 1, including the steps of hydraulically inducing the pressure applied to said female mold section bearing against said vibrating male mold section.

7. A process for forming molded sugar articles as set forth in claim 1, including the step of mechanically inducing the pressure applied to said female mold section bearing against said vibrating male mold section.

8. A process for forming molded sugar articles as set forth in claim 1, wherein the pressure applied to said female mold section bearing against said vibrating male mold section is mechanically induced.

9. A process for forming molded sugar articles as set forth in claim 1, wherein a plurality of female mold sections are filled simultaneously, each of said female mold sections being simultaneously brought to bear against corresponding male mold sections under pressure, each of said male mold sections vibrating against said moistened granulated sugar compacting said sugar, said female mold sections thereafter being placed on mechanical conveyor means and passed into said zone of dehumidified heat and thereafter cooled within a dehumidifying cooling chamber, said female mold sections then being deposited on a second vibrating surface to break said molded sugar articles free 'from said female mold sections.

References Cited UNITED STATES PATENTS FOREIGN PATENTS 1/1949 Great Britain.

WALTER A. SCHEEL, Primary Examiner.

15 JOSEPH SHEA, Assistant Examiner.

US. Cl. X.R. 

